Operator Manual

RV Generator Set

HDKCA
HDKCB

English 1−2009 981−0173 (Issue 5)

 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Emissions Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

i
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintaining the Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting With Table 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

ii
SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL • Engine cooling air must not be used for heating
before operating the genset. Safe operation and the vehicle.
top performance can only be obtained when
equipment is properly operated and main- GENERATOR VOLTAGE IS DEADLY
tained.
• Disable the automatic genset starting feature
The following symbols in this manual alert you to (AGS) of an inverter-charger or other automat-
potential hazards to the operator, service person ic starting device before servicing the genset to
and equipment. avoid electric shock from an unexpected start.
• Generator electrical output connections must
DANGER alerts you to an immediate hazard be made by a trained and experienced electri-
that will result in severe personal injury or cian in accordance with applicable codes.
death.
• The genset must not be connected to shore
WARNING alerts you to a hazard or unsafe power (utility). Back-feed to shore power can
practice that can result in severe personal inju- cause electrocution and damage to equip-
ry or death. ment. An approved switching device must be
used to prevent interconnections.
CAUTION alerts you to a hazard or unsafe • Use caution when working on live electrical
practice that can result in personal injury or equipment. Remove jewelry, make sure cloth-
equipment damage. ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
When equipped with an integral or add−on Auto- with insulated handles.
matic Generator Starting System (AGS) control,
exhaust carbon monoxide (CO), electric shock, and DIESEL FUEL IS COMBUSTIBLE
moving parts hazards are possible due to unex-
pected starting. Turn off AGS whenever performing • Do not smoke or turn electrical switches ON or
maintenance or service, when the vehicle is stored OFF where fuel fumes are present or in areas
between uses, is awaiting service, or is parked in a sharing ventilation with fuel tanks or equip-
garage or other confined area. ment. Keep flames, sparks, pilot lights, arc-
producing equipment and all other sources of
ENGINE EXHAUST IS DEADLY ignition well away.
• Inspect for exhaust leaks at every startup and • Fuel lines must be secured, free of leaks and
after every eight hours of running. separated or shielded from electrical wiring.
• Learn the symptoms of carbon monoxide poi-
soning in the genset Operator’s Manual. MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a • Disable the automatic genset starting feature
working carbon monoxide detector. (AGS) of an inverter-charger or other automat-
ic starting device before servicing the genset to
• Do not operate the genset when the vehicle is avoid unexpected starting.
parked in a confined space, such as a garage.
• Do not wear loose clothing or jewelry near
• Disable the AGS feature of an inverter-charger moving parts such as PTO shafts, fans, belts
or other automatic starting device before stor- and pulleys.
ing the vehicle or parking it in a garage or other
confined space. • Keep hands away from moving parts.
• The exhaust system must be installed in accor- • Keep guards in place over fans, belts, pulleys,
dance with the genset Installation Manual. and other moving parts.

iii
 BATTERY GAS IS EXPLOSIVE • Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
• Wear safety glasses. gear stowed in the compartment can restrict
• Do not smoke. cooling air.
• To reduce arcing when disconnecting or recon- • Make sure all fasteners are secure and
necting battery cables, always disconnect the torqued properly.
negative (−) battery cable first and reconnect • Do not work on the genset when mentally or
it last. physically fatigued or after consuming alcohol
or drugs.
FLAMMABLE VAPOR CAN CAUSE A
• You must be trained and experienced to make
DIESEL ENGINE TO OVERSPEED adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
Flammable vapor can cause a diesel engine to
vere personal injury or death.
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and • Used engine oil has been identified by some
death. Do not operate a diesel-powered genset U. S. state and federal agencies as causing
where a flammable vapor environment can be cancer or reproductive toxicity. Do not ingest,
created by fuel spill, leak, etc. The owners and inhale, or contact used oil or its vapors.
operators of the genset are solely responsible for • Ethylene glycol, used as engine antifreeze, is
operating the genset safely. toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
GENERAL PRECAUTIONS dance with local environmental regulations.
• Keep children away from the genset. • Keep multi-class ABC fire extinguishers readi-
• Do not use evaporative starting fluids. They ly at hand. Class A fires involve ordinary com-
are highly explosive. bustible materials such as wood and cloth.
Class B fires involve combustible and flam-
• To prevent accidental or remote starting while mable liquids and gaseous fuels. Class C fires
working on the genset, disconnect the nega- involve live electrical equipment. See NFPA
tive (−) battery cable at the battery. No. 10 (Portable Fire Extinguishers) or equiva-
• Let the engine cool down before removing the lent—BS EN 3-7:2004.
coolant pressure cap or opening the coolant • Genset installation and operation must comply
drain. Hot coolant under pressure can spray with all applicable local, state and federal
out and cause severe burns. codes and regulations.

Mobile-8

iv
1. Introduction
ABOUT THIS MANUAL
This is the Operator’s Manual for the generator sets
(gensets) listed on the front cover. Read and care-
fully observe all of the instructions and precautions
in this manual. Keep this manual and the genset
Installation Manual with the other vehicle manuals.

Operation, Periodic Maintenance and Trouble-

shooting provide the instructions necessary for op-
erating the genset and maintaining top perfor-
mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).

WARNING This genset is not a life support sys-

tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A per-
sonal attendant, redundant power or alarm sys-
tem must be used if genset operation is critical.

WARNING Improper service or replacement of

parts can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.

Unauthorized modifications or replacement of

fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.

NAMEPLATE
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan
for parts, service or information. Figure 1-1 illus- FIGURE 1-1. TYPICAL NAMEPLATE
trates the nameplate and its location. The gray
boxes illustrate where to look for the model and seri-
al numbers.
MODEL NUMBER: ___________________________
Record these numbers in Figure 1-2 so that they are
easy to find when needed. Each character in these SERIAL NUMBER: ___________________________
numbers is significant. The last character of the
model number is the specification letter, which is im-
portant for obtaining the right parts. Genuine FIGURE 1-2. RECORD NUMBERS HERE
Onan® replacement parts are recommended for
best results. Refer to the genset Parts Catalog.

1-1
 HOW TO OBTAIN SERVICE RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
When you call for service, parts, or product literature
(such as the Service Manual or Parts Catalog) for If you have difficulty in arranging service or resolv-
your genset, contact the nearest authorized Cum- ing a problem, please contact the Service Manager
mins Onan distributor. Cummins Onan has factory- at the nearest Cummins Onan distributor for assis-
trained representatives to handle your requests for tance.
genset parts and service. For information for con-
tacting our distributors worldwide, go to internet site Outside North America
www.cumminsonan.com.
If you are outside North America, call Cummins
In North America Onan at 1−763−574−5000 from 7:30 AM to
4:00 PM, Central Standard Time, Monday through
Call 1-800-888-ONAN to contact the nearest Cum- Friday, or fax 1−763−528−7229.
mins Onan distributor in the United States or Cana-
da. (This automated service utilizes touch-tone Information to Have Ready
phones only). Select OPTION 1 (press 1) to be au-
tomatically connected to the distributor nearest to Before calling for service, have the following infor-
you. mation available:
If you are unable to contact a distributor using the 1. The complete genset model number and serial
automated service, consult the Yellow Pages. Typi- number. See About This Manual (Page 1-1).
cally, our distributors are listed under: 2. The date of purchase
GENERATORS − ELECTRIC, 3. The nature of the problem. See Section 4. Trou-
ENGINES − GASOLINE OR DIESEL, or bleshooting.

1-2
 ENGINE EMISSIONS COMPLIANCE
The label that states compliance with applicable en-
gine emissions regulations is located on the side of
the Power Unit, as shown circled in Figure 1-3. Re-
fer also to the FEDERAL EMISSION DESIGN AND
DEFECT LIMITED WARRANTY FOR C. I. EN-
GINES (DIESELS) that was shipped in the same
package as the Operator’s Manual.

FIGURE 1-3. EMISSIONS LABEL LOCATION

1-3
 TYPICAL GENSET cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
Figure 1-4 illustrates the fuel, battery, remote con- shown are the combustion air inlet and oil drain
trol and AC output connection points, the flow of openings in the base.

AC OUTPUT AND REMOTE MAINTENANCE FUEL EXHAUST

CONTROL CONNECTIONS ACCESS CONNECTIONS CONNECTIONS

CONTROL BATTERY
PANEL CONNECTIONS

COOLING & VENTILATING AIR IN HOT AIR OUT

FIGURE 1-4. TYPICAL GENSET

1-4
2. Operation

FUEL RECOMMENDATIONS ENGINE OIL RECOMMENDATIONS

WARNING Diesel fuel is combustible and can Oil Performance Class

cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip- Use API (American Petroleum Institute) classified
ment or in areas sharing ventilation with such engine oils according to the following guidelines:
equipment. Keep flames, sparks, pilot flames, • Emissions-Regulated Areas: It is mandatory
electrical arcs and switches and all other to use CF, CF−4, CG−4, CH−4 or CI−4 class oil
sources of ignition well away. Keep a multi- with low sulfur fuel (sulfur content less than 500
class ABC fire extinguisher handy. ppm, 0.05% weight) or ultra low sulfur fuel (sul-
fur content less than 15 ppm, 0.0015% weight).
High quality diesel fuel is necessary for good perfor-
mance and long engine life. • Non-Regulated Areas: CF class oil is recom-
mended when using high sulfur fuel—sulfur
• The specifications for the type and sulfur con- content between 500 ppm (0.05% weight) and
tent (ppm, % weight) of the diesel fuel used 5000 ppm (0.5%weight). If CF−4, CG−4, CH−4
must comply with all emissions regulations ap- or CI−4 class oil is used, the oil and oil filter
plicable in the areas where the genset is to be must be changed twice as often as specified in
operated. the PERIODIC MAINTENANCE SCHEDULE
• Diesel fuels meeting ASTM D975 or EN 590 (Page 3-1).
specifications are recommended. Use Grade • Non-Regulated Areas: Use CF, CF−4, CG−4,
1-D diesel fuel where ambient temperatures CH−4 or CI−4 class oil when using high sulfur
are below 14° F (−10° C). A minimum Fuel Ce- fuel—sulfur content between 5000 ppm (0.5%
tane Rating of 45 is recommended. Where am- weight) and 10,000 ppm (1.0% weight). The oil
bient temperatures are below −4 F (−20° C), or and oil filter must be changed twice as often as
the elevation is above 5000 ft (1500 m), a mini- specified in the PERIODIC MAINTENANCE
mum Cetane Rating of 50 is recommended. SCHEDULE (Page 3-1).
• Current US EPA regulations for Non-Road en-
gines limit diesel fuel sulfur content to a maxi- Oil Viscosity
mum of 500 ppm (0.05% weight). Therefore,
use Grade 2-D S500 or 2-D S15 diesel fuel. Look for the SAE (Society of Automotive Engineers)
Where ambient temperatures are below 14° F viscosity grade. Referring to Figure 2-1, choose the
(−10° C), use Grade 1-D S500 or 1-D S15 die- viscosity grade appropriate for the ambient temper-
sel fuel. Note that beginning in year 2010, US atures expected until the next scheduled oil change.
EPA regulations for Non-Road engines will limit Multi-grade oils such as SAE 15W-40 are recom-
diesel fuel sulfur content to a maximum of 15 mended for year-round use.
ppm (0.0015% weight).
• Do not use diesel fuel having a sulfur content
greater than 10,000 ppm (1.0% weight).
• Diesel fuel must meet the ASTM D975 stan-
dard for lubricity and pass a minimum load level
of 3100 grams as measured by ASTM D6078,
or maximum scar diameter of 0.45 mm as mea-
sured by ASTM D6079 or ISO 12156−1.
• B5 Bio-Diesel fuel that meets industry specifi-
cations and quality is suitable for use with this
genset. FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE

2-1
 RECOMMENDED COOLANT the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see
Use the best quality ethylene glycol antifreeze solu- Section 4. Troubleshooting).
tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers and mixed with (Rapid blinking before cranking starts indicates that
fresh (distilled) water that is low in minerals and cor- the glow plugs are preheating the combustion
rosive chemicals. A 50/50 mixture is recommended- chambers. The genset controller automatically var-
for all climates and is suitable for temperatures ies the time based on engine temperature.)
down to -34° F (-37° C).
Line Circuit Breaker(s) − The line circuit breakers
See Section 5. Specifications for coolant capacity. protect the AC power leads connected to the gen-
set.
STARTING BATTERIES
Coolant Recovery Tank Fill Cap − The recovery
The genset requires a 12 volt battery to power its tank provides for coolant expansion. Replenish the
control and starting circuits. Reliable genset starting normal loss of coolant by filling here.
and starter service life depend upon adequate bat-
tery system capacity and maintenance. Hour Meter − The hour meter records the total run-
ning time of the genset. It cannot be reset.
See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (p. 3-4) and Section 5. Specifi- REMOTE CONTROL PANEL
cations for minimum required battery ratings.
There probably is a remote genset control panel in-
CONTROL PANEL side the vehicle. Three control panel kits are avail-
able:
The control panel (Figure 2-2) has the following fea- • Remote switch / status lamp
tures:
• Remote switch / status lamp and hour meter
Control Switch − This switch is used to start and • Remote switch / status lamp and DC voltmeter
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light). The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
Status Lamp − This is a lamp in the control switch the indicator consistently stays above or below the
that blinks rapidly during preheat and cranking. It normal zone, see MAINTAINING THE BATTERY
stays on continuously while the genset is running. If AND BATTERY CONNECTIONS (p. 3-4).

2-2
 LINE CIRCUIT COOLANT RECOVERY
BREAKER(S) TANK FILL CAP

COOLANT RECOVERY
TANK FLUID LEVEL

CONTROL SWITCH
&STATUS LAMP

HOUR METER

FIGURE 2-2. CONTROL PANEL

2-3
 WARNING EXHAUST GAS is deadly. All en- PRIMING THE FUEL SYSTEM
gine exhaust contains carbon monoxide; an
odorless, colorless, poisonous gas that can The fuel system should be primed after replacing
cause unconsciousness and death. Symptoms the fuel filter or running the genset out of fuel. To
of carbon monoxide poisoning include: prime the fuel system, hold the control switch down
• Dizziness • Headache in its Stop position for at least half a minute. (Shut-
• Nausea • Weakness and Sleepiness down Code No. 57, Overprime, occurs after 3 min-
• Vomiting • Inability to Think Coherently utes of holding the switch down. See Section 4.
Troubleshooting.)
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If MANUAL STARTING
symptoms persist, seek medical attention. Shut
down the genset and do not operate it until it has The genset can be started and stopped from the
been inspected and repaired. genset control panel or from a remote panel.
Never sleep in the vehicle while the genset is 1. Perform the PRE-START CHECKS, prime the
running unless the vehicle has a working car- fuel system if necessary, and turn off the air
bon monoxide detector. The exhaust system conditioners and other large electrical loads.
must be installed in accordance with the genset
Installation Manual. Make sure there is ample 2. Push and hold Start until the genset starts. The
fresh air when operating the genset in a con- status lamp will come on when the genset starts
fined area. and will stay on while it runs. While starting it will
blink rapidly indicating preheating and crank-
PRE-START CHECKS ing. (Depending on how cold it is, preheating
can take up to 15 seconds, extending the time
Before the first start of the day and after every eight that the lamp blinks.)
hours of operation, inspect the genset as instructed
under GENERAL INSPECTION (p. 3-2). Keep a log CAUTION Excessive cranking can over-
of maintenance and the hours run and perform any heat and damage the starter motor. Do not
maintenance that may be due. See Returning the crank for more than 30 seconds at a time.
Genset to Service (p. 2-7) if the vehicle has been in Wait at least 2 minutes before trying again.
storage.
3. See Section 4. Troubleshooting if the genset
Before each start: does not start after several tries.
1. Make sure all vehicle carbon monoxide (CO) 4. Let the genset warm up a few minutes until it is
detectors are working. running smoothly before connecting the ve-
2. Check for fuel, oil and coolant leaks and dam- hicle electrical loads (appliances).
age to the exhaust system.
5. Check for fuel, oil, coolant and exhaust leaks.
3. To prevent overheating and to reduce fouling Stop the genset immediately if there is leak and
with dust and debris, make sure the genset’s have it repaired.
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects. MANUAL STOPPING
Repark the vehicle if necessary and/or remove
any objects blocking the air inlet or air outlet. Run the genset under no load for a few minutes to
4. Turn off air conditioners and other large ap- allow the engine to cool down and then push and re-
pliances. lease Stop.

2-4
 AUTOMATIC STARTING AND STOPPING to obtain the individual appliance loads. It may be
necessary to run fewer appliances at the same
The vehicle may be equipped with an inverter-char- time—the sum of the loads must not be greater
ger or other automatic genset starting device than genset rating.
(AGS). Always follow the instructions and safety
precautions provided by the manufacturer of the au- The genset may shut down due to overload when a
tomatic starting device when enabling automatic large motor or air conditioner is started or cycles off
genset starting. and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
WARNING EXHAUST GAS is deadly. MOV- a motor’s startup load is much larger than its running
ING PARTS and ELECTRICITY can cause severe load. It may be necessary to run fewer ap-
personal injury or death. To reduce exposure to pliances when large motors and air condition-
these hazards, always disable automatic genset ers are cycling on and off.
starting before:
Maximum power decreases as altitude increases
S Sleeping in vehicle, unless vehicle has a because air density decreases. For every 1000-foot
working CARBON MONOXIDE detector (305 m) increase in elevation you can expect power
S Parking vehicle in garage or confined space to decrease approximately 3.5 percent. See
Table 2-2. It may be necessary to run fewer ap-
S Parking vehicle for storage pliances at higher altitudes.
S Servicing genset TABLE 2-1. TYPICAL APPLIANCE LOADS
S Servicing batteries Appliance Load (watts)
S Servicing electrical appliances Air Conditioner 1400-2000
Battery Charger Up to 3600
S Fueling vehicle
DC Converter 300-900
LOADING THE GENSET Refrigerator 600-1000
Microwave Oven 1000-1500
The genset can power AC motors, air conditioners, Electric Frying Pan or Wok 1000-1500
AC/DC converters, battery chargers and other ap- Electric Stove Element 350-1000
pliances. How much appliance load* can be pow-
Electric Water Heater 1000-1500
ered depends upon the genset power rating. The
genset will shut down or its circuit breakers will trip if Electric Iron 500-1200
the sum of the loads exceeds genset power. See Electric Hair Dryer 800-1500
Section 4. Troubleshooting. Coffee Percolator 550-750
Television 200-600
To avoid overloading the genset and causing shut- Radio 50-200
downs, compare the sum of the loads of the ap-
Electric Drill 250-750
pliances that are likely to be used at the same time to
the power rating of the genset. Use Table 2-1 or the Electric Broom 200-500
ratings on the appliances themselves (if so marked) Electric Blanket 50-200

TABLE 2-2. POWER VS. ALTITUDE

Altitude
Maximum Power Maximum Power
(Elevation above Sea Level)
at/below 500 ft (152 m) 10,000 W (genset rating) 12,500 W (genset rating)
at 2500 ft (762 m) 9300 W 11,620 W
at 5500 ft (1676 m) 8250 W 10,300 W
8250 W minus 10,300 W minus
above 5500 ft (1676 m) 350 W every 440 W every
1000 ft (305 m) 1000 ft (305 m)

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

2-5
 RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (Page 2-1). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (Page 2-1).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (Page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE

WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (Page 2-5).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power genset compartment. Keep the genset clean.
must have an approved device to keep the genset
and utility from being interconnected. See the gen- 2. Perform air cleaner maintenance more often.
set Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
WARNING Interconnecting the genset and the 3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (Page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.

2-6
 BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker OFF
hours. See LOADING THE GENSET (Page 2-5). (Page 2-6).
3. Change the engine oil and attach a tag indicat-
Proper engine oil and oil level are especially critical ing oil viscosity. See ENGINE OIL REC-
during break-in because of the higher engine tem- OMMENDATIONS (Page 2-1).
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during 4. Disconnect the battery cables (negative [−]
break-in. See ENGINE OIL RECOMMENDATIONS cable first) from the starting battery and store
(Page 2-1). Check oil level twice a day or every the battery according to the battery manufac-
4 hours during the first 24 hours of operation and turer’s recommendations. See MAINTAINING
change the oil and oil filter after the first 50 hours of THE BATTERY AND BATTERY CONNEC-
operation. TIONS (Page 3-4).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(Page 2-5). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-1).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (Page 3-4).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
STORING THE GENSET (Page 3-4).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (Page 3-2).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(Page 2-6) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.

2-7
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- any engine repair establishment or individual. How-
mance and long genset life. Use Table 3-1 as a ever, warranty work must be completed by an au-
guide for normal periodic maintenance. In hot and thorized Cummins Onan dealer.
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Maintenance, replacement or repair of emission nect the negative (−) cable at the battery to pre-
control devices and systems may be performed by vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE TASK After Every Every Every Every Every

Every Every
First 50 250 500 800 1500 3000 Page
Day Month
Hrs Hrs Hrs Hrs Hrs Hrs
General Inspection • 3-2
Check Engine Oil Level • 3-2
Check Engine Coolant Level • 3-7
Check Battery & Battery Connections1 • 3-4
Change Engine Oil & Oil Filter1, 2, 3, 4 • • 3-3
Clean Spark Arrestor3 • 3-5
Replace Engine Air Filter2, 3 • 3-4
Replace Fuel Filter3 • 3-6
Adjust Engine Valve Lash7 • −
Flush Coolant System5 • 3-7
Replace Coolant Pressure Cap5 • 3-7
Replace V-Belt & Coolant Hoses6, 7 • −
Check Fuel Injector Pressure7, 8 • −
Check Generator Slip Rings /
• −
Brushes2,7

Replace Generator Bearing7 • −

1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Perform every 125 hours when using high sulfur fuel. See ENGINE OIL RECOMMENDATIONS (Page 2-1).
5. Perform at least once every two years.
6. Perform at least once every five years.
7. Must be performed by trained and experienced personnel (authorized Onan service representatives).
8. EPA requirement.

3-1
 GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.

Oil Level Fuel System

Check engine oil level (Figure 3-1). Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
Engine Coolant System while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
CAUTION Operating the genset when coolant line is not rubbing against other parts. Replace worn
level is low can cause serious engine damage. or damaged fuel line parts before leaks occur.

Check the engine coolant level and look for coolant WARNING Diesel fuel leaks can lead to fire. Do
leaks around the bottom of the genset and on the not operate the genset if operation causes fuel
ground below. Minor leaks that can be replenished to leak.
by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician Prime the fuel system if the genset ran out of fuel.
as soon as possible. Larger leaks are cause for
shutting down the genset until it can be repaired. Battery Connections
Exhaust System Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
WARNING EXHAUST GAS IS DEADLY! Do not
electrical resistance which makes starting harder.
operate the genset if there is an exhaust leak or See MAINTAINING THE BATTERY AND BATTERY
any danger of exhaust gases entering or being CONNECTIONS (p. 3-4).
drawn into the vehicle.
Mechanical
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
Look for mechanical damage and listen for unusual
found and have it repaired before operating the gen-
noises. Check the genset mounting bolts.
set again.

Look for openings or holes between the genset To prevent overheating and to reduce fouling with
compartment and vehicle cab or living space if the dust and debris, make sure the genset’s normal
genset engine sounds louder than usual. Have all ground clearance is not being reduced by sloping
such openings or holes closed off or sealed to pre- ground, curbs, logs or other objects. Repark the ve-
vent exhaust gases from entering the vehicle. hicle if necessary and/or remove any objects block-
ing the air inlet or air outlet.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at CHECKING ENGINE OIL LEVEL
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle. WARNING State and federal agencies have de-
termined that contact with used engine oil can
WARNING Do not park the vehicle in high grass cause cancer or reproductive toxicity. Avoid
or brush. Contact with the exhaust system can skin contact and breathing of vapors. Use rub-
cause a fire. ber gloves and wash exposed skin.
1. Park the vehicle on level ground, shut down the
Park the vehicle so that the genset exhaust gases
genset and remove the front access door.
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and oth- 2. Pull out the oil dip stick, wipe it clean, reinsert
er vehicles can cause exhaust gases to accumulate it and pull it out again to check the oil level (Fig-
in and around the vehicle. ure 3-1).

3-2
 3. Add or drain oil as necessary. See REC- 2. Remove the front access door and the oil fill
OMMENDED ENGINE OIL (p. 2-1). Keep the cap, unscrew the oil drain plug and drain all the
oil level between the FULL and ADD marks. oil from the engine. Reinstall the oil drain
plug securely.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe 3. Spin off the oil filter canister and clean the filter
engine damage. Keep the oil level between mounting surface on the engine block. Remove
the FULL and ADD marks. the old gasket if it remains.
4. Reinsert the dipstick and secure the oil fill cap 4. Make sure the gasket is in place on the new fil-
and front access door. ter and apply a thin film of clean oil to the gas-
ket. Spin the new filter on until the gasket just
CHANGING ENGINE OIL AND OIL FILTER touches the block. Turn it an additional 1/2 to
3/4 turn. Do not overtighten.
Refer to Table 3-1 for scheduled engine oil change.
Change oil more often in hot and dusty environ- 5. Refill with 5.9 quarts (5.6 liters) of oil, check oil
ments. level (Figure 3-1) and secure the front access
door.
1. Place a pan under the oil drain plug (Fig-
ure 3-1), run the genset until warm and shut it 6. Dispose of the used oil and oil filter according
off. to local environmental regulations.

FILTER

DIP STICK

FILL CAP

DRAIN PLUG
(22 MM HEX HEAD)

FIGURE 3-1. ENGINE OIL MAINTENANCE

3-3
 MAINTAINING THE BATTERY AND 2. Remove battery cables with a battery terminal
BATTERY CONNECTIONS puller.
3. Make sure which terminal is positive (+) and
WARNING Arcing at battery terminals or in which is negative (−) before making battery
light switches or other equipment, and flames or connections, always removing the negative (−)
sparks, can ignite battery gas causing severe cable first and reconnecting it last to reduce
personal injury—Ventilate battery area before arcing.
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON REPLACING THE AIR FILTER ELEMENT
or OFF away from battery—Stop genset and dis-
connect charger before disconnecting battery Refer to Table 3-1 for scheduled air filter replace-
cables—Disconnect negative (−) cable first and ment. Replace it more often in dusty environments.
reconnect last. The air filter is accessible through the front access
door (Figure 3-2). Loosen the three screws that se-
Refer to Table 3-1 for scheduled battery mainte- cure the coolant recovery tank to the housing top
nance, and follow the battery manufacturer’s in- panel and move it out of the way. Loosen the two
structions. Have the battery charging system ser- screws that secure the air filter housing to the hous-
viced if DC system voltage is consistently low or ing top panel so that the spring clips that secure the
high. Always: filter housing end cap can be unlatched. Remove
1. Keep the battery case and terminals clean and the end cap and replace the filter element. Secure
dry and the terminals tight. the filter housing, coolant tank and access door.

COOLANT
RECOVERY TANK AIR FILTER HOUSING
(SHOWN CUT AWAY) END CAP

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

3-4
 CLEANING THE SPARK ARRESTOR 1. Remove the top enclosure panel.

Refer to Table 3-1 for scheduled cleaning of the 2. Remove the cleanout plug from the muffler. Se-
spark arrestor muffler (which meets U.S. Forest cure the top enclosure panel before running the
Service requirements). Cleaning is required for genset. With the cover in place there will be
maximum genset performance. enough air flow to cool the engine properly and
WARNING A hot muffler can cause severe carry the soot out of the compartment.
burns. Let the muffler cool down before remov-
ing or installing the cleanout plug. 3. Start the genset and load it nearly to full power.
Let the genset run for about five minutes to ex-
The muffler is mounted inside the genset housing pel the soot.
(Figure 3-3). The spark arrestor cleanout plug is lo-
cated on the side of the muffler and is accessible by 4. Stop the genset, allow the muffler to cool down,
removing the top enclosure panel. Clean out the reinstall the cleanout plug and secure the top
muffler as follows: panel.

CLEANOUT PLUG
(11/16 INCH HEX HEAD)

REMOVE THIS PANEL

FOR ACCESS

MUFFLER

FIGURE 3-3. SPARK ARRESTOR CLEANOUT PLUG

3-5
 REPLACING THE FUEL FILTER hoses, use a flare nut wrench on the hose flare nuts,
so as not to round the corners, and a second wrench
See Table 3-1 for scheduled fuel filter replacement. on the filter fitting, so as not to stress the fitting. (Re-
A dirty fuel filter may be the cause of a failure to start. moving the bracket screws first will make the job
The fuel filter is accessible through the front access easier.)
door (Figure 3-4).
CAUTION Dirt can damage the fuel system.
WARNING Diesel fuel is combustible and can Make sure to wipe dirt off the fuel hose fittings
cause severe personal injury or death. Do not before disconnecting.
smoke near diesel fuel tanks or equipment.
Keep flames, sparks, pilot lights, electrical Dispose of the fuel filter and paper towels in accor-
switches, arc-producing equipment and all oth- dance with local regulations.
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.
Installing the Fuel Filter
Close any fuel line shutoff valve before discon-
necting the fuel line from the filter. Rotate the filter half a turn around its mounting stud
if the fittings interfere with the bracket. It only fits one
Accidental or remote starting can cause severe way.
personal injury or death. Disconnect the nega-
tive (−) cable at the battery to prevent starting Connect the fuel fittings before tightening the filter
while working on the genset. mounting nut. Take care not to crossthread the fuel
fittings. Thread them in by hand and tighten one flat
Removing the Fuel Filter past seating with two wrenches.

Use paper towels to clean the two fuel hose fittings Prime the fuel system for half a minute to fill the new
and absorb any fuel that spills. To disconnect the filter with fuel and then secure the access door.

HOSE TO FUEL
ENGINE FILTER

FILTER
MOUNTING NUT

BRACKET
HOSE FROM MOUNTING
FUEL PUMP SCREWS

FIGURE 3-4. FUEL FILTER

3-6
 MAINTAINING THE ENGINE COOLING Flush and clean the cooling system before refilling.
SYSTEM Radiator cleaning chemicals are available at local
auto parts stores. Follow the instructions for clean-
Refer to Table 3-1 for scheduled maintenance. The ing and flushing that come with the cleaning solu-
engine cooling system is filled at the factory with a tion.
50/50 mixture of ethylene glycol anti-freeze and
water, which is suitable for temperatures down to Refilling Cooling System
-34° F (-37° C).

Recommended Coolant Install the coolant drain plug using pipe thread seal-
ant. Tighten it just enough so that it does not leak
See RECOMMENDED COOLANT (p. 2-2). when the genset is running and has warmed up.

Pressure Cap Pull the hose connected to the pressure cap assem-
bly out as far and as high as it will go (Figure 3-5).
Replace the pressure cap (Figure 3-5) every two
Remove the pressure cap and fill the system using a
years (seals deteriorate and leak). Proper cooling
funnel inserted into the fill hose to prevent coolant
system pressure (14 psi) is essential for optimal en-
from entering the vent hose and blocking the es-
gine cooling and minimal coolant loss.
cape of air as the system fills. The system will seem
Draining and Cleaning Cooling System full when it actually is not if the air cannot escape
through the vent hose. If the vent hose does get
WARNING Hot coolant spray can cause severe blocked, pinch the overflow hose and blow the vent
burns. Let the engine cool before releasing the hose clear. Start and operate the genset for a few
pressure cap or removing the drain cap. minutes while keeping the fill opening elevated to
promote venting of air from the coolant. Shut down
Accidental or remote starting can cause severe the genset and add coolant as necessary. Secure
personal injury or death. Disconnect the nega- the pressure cap and fill the recovery tank to the
tive (−) cable at the battery to prevent starting COLD mark.
while working on the genset.
CAUTION Coolant trapped in the vent hose
Let the engine cool before removing the pressure will prevent the system from filling to its
cap. Relieve any remaining pressure by turning the capacity, which can lead to serious engine
pressure cap slowly, without pushing down. When damage.
the pressure has been relieved, push down on the
cap, turn it the rest of the way and withdraw it. Then
remove the coolant drain plug (Figure 3-5) and Coolant Level Check
drain the coolant into a suitable container.
Check coolant level in the recovery tank (Fig-
WARNING Ethylene glycol antifreeze is con- ure 3-5) before the first startup of each day and fill to
sidered toxic. Dispose of it according to local the COLD mark if necessary with Recommended
regulations for hazardous substances. Coolant.

3-7
 PRESSURE CAP
COOLANT RECOVERY AND SYSTEM
TANK FILL OPENING

RECOVERY TANK
FILL CAP (BLUE)

COOLANT
LEVEL

COOLANT DRAIN PLUG

(1/4 INCH HEX SOCKET)

FIGURE 3-5. ENGINE COOLING SYSTEM

3-8
4. Troubleshooting
TROUBLESHOOTING WITH TABLE 4-1 • Two blinks indicate shutdown due to a loss of
engine oil pressure.
To aid troubleshooting the genset controller causes • Three blinks indicate a service fault. Press
the status indicator light to blink the numeric code Stop once to cause the two-digit, second-level
assigned to the fault that caused shutdown. For a shutdown code to blink. (Pressing Stop again
brief description of the fault and step-by-step cor- will stop the blinking.) The two-digit code con-
rective action, refer to TABLE 4-1. TROUBLE- sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
SHOOTING, which lists the fault codes in numerical then 1 to 9 blinks. The first set of blinks repre-
order. sents the tens digit and the second set of blinks
the units digit of the shutdown code number.
If you are unable to resolve the problem after taking For example, shutdown code No. 36 appears
the corrective actions suggested, contact an autho- as:
rized Onan dealer. See HOW TO OBTAIN SER-
VICE (p. 1-2). blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
long pause—repeat
Note: Many genset shutdowns can be avoided by • Four blinks indicate that cranking time ex-
performing periodic maintenance on schedule ceeded 35 seconds.
(TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE)
and by not running the genset out of fuel. Note that • To avoid the possibility of anyone misinterpreting
when the genset and propulsion engine draw from Code Nos. 3 and 4 as Code Nos. 33 and 44, the lat-
the same fuel tank, the fuel dip tubes are usually ar- ter have not been assigned faults.
ranged so that the genset will run out of fuel first. By
marking the genset empty point on the fuel gauge, it RESTORING FAULT CODE BLINKING
will be easier to tell when the genset may run out of
fuel. Blinking continues for five minutes and stops. To re-
store blinking press the control switch to STOP
FAULT CODE BLINKING (Prime) until the light comes on (3 to 4 seconds).
Then press STOP (Prime) three times to restores
At fault shutdown, the status indicator light will re- blinking.
peatedly blink sets of 1, 2, 3 or 4 blinks.
Note: The last fault logged will blink even though the
• One blink indicates shutdown due to high en- condition that caused the shutdown may have been
gine coolant temperature. corrected.

4-1
 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

NO RESPONSE AT CONTROL SWITCH

(Faulty switch, poor or missing connections, dead battery)
Corrective Action:
1. Try the genset (local) control switch if there is no response at the remote control switch, and vice
versa.
2. Check for 12 VDC across genset battery cable terminal block. Service as necessary by cleaning and
tightening battery cable connections, recharging or replacing the battery or replacing damaged or
missing battery cables.

THE STARTER ENGAGES AND DISENGAGES

(Low cranking voltage)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.

THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE

(Marginal battery, battery connections or charging system)
Corrective Action:
1. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
2. Have the battery recharging system serviced.

NO AC POWER WHEN GENSET IS RUNNING

(A Circuit Breaker is OFF, tripped or malfunctioning or there are poor AC harness connections)
Corrective Action:
1. Reset or turn ON genset circuit breaker CB1.
2. Reset or turn ON any other circuit breaker in the AC power supply system.

PERSISTENT, AUDIBLE ENGINE SURGING—WITHOUT FAULT SHUTDOWN

(Fuel leaks, restrictions or air bubbles, worn slip rings/brushes, misadjusted or faulty governor,
worn generator bearing)
Corrective Action:
1. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
2. Replace the fuel filter (p. 3-6).

4-2
 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

ENGINE OVER TEMPERATURE—CODE NO. 1

(During normal operation engine coolant temperature exceeded 239° F [115° C] for 10 seconds)
Corrective Action:
1. Check engine coolant level, add coolant as necessary and repair any leaks.
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset
and clean out dirt fouling the radiator passages.
3. Run fewer appliances at the same time to keep down engine temperature. (Note that high altitude
and high ambient temperature decrease engine cooling capacity.)

LOW OIL PRESSURE—CODE NO. 2

(During normal operation engine oil pressure dropped to less than
14 psi [97 kPa] for 3 seconds—switch closed)
Corrective Action:
1. Check engine oil level, add oil as necessary and repair any leaks.
2. Drain the excess oil if the level is above Full on the dipstick. If the level is too high the crankshaft can
whip the oil into foam, which the pump can’t pump.)

SERVICE CHECK—CODE NO. 3

(A second-level fault occurred)
Corrective Action: Check the second-level fault code by momentarily pressing Stop. The second-lev-
el fault will be one of the following in this table.

OVER CRANK—CODE NO. 4

(First-level fault code—Cranking time exceeded 35 seconds)
Corrective Action:
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-4).
3. Check the engine air filter and remove any blockage (p. 3-4).
4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
5. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
6. Replace the fuel filter (p. 3-6).

OVER VOLTAGE—CODE NO. 12

(After voltage regulation was enabled Output Voltage jumped to more than 125% of rated for 75 millisec-
onds or to more than 115% of rated for 3 seconds)
Corrective Action: See an authorized Onan dealer.

4-3
 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

UNDER VOLTAGE—CODE NO. 13

(After voltage regulation was enabled Output Voltage fell to less than 90% of rated for 5 seconds)
Corrective Action: Turn OFF the line circuit breaker on the operator’s console. If the genset now
runs, run it with fewer connected loads.

OVER FREQUENCY—CODE NO. 14

(After the starter was engaged Frequency jumped to more than 70 Hz for 40 milliseconds, or to more
than 55/66 Hz [50/60 Hz rated] for 6 seconds)
Corrective Action:
1. Check for a tripped genset circuit breaker, reset it if necessary, and run with fewer connected loads.
(A breaker tripping under load can cause genset frequency to overshoot.)
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can
disrupt frequency.)

UNDER FREQUENCY—CODE NO. 15

(During normal operation Frequency fell to less than 44/54 Hz [50/60 Hz rated] for more than 8 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF and restart the genset. If the genset now runs, run it with fewer
connected loads, especially those with high motor starting loads such as air conditioners.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can dis-
rupt frequency.)
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-4).
4. Replace the fuel filter (p. 3-6).

ACTUATOR SHORTED OR OPEN—CODE NO. 19

(At startup the Controller sensed an open or shorted governor actuator/harness)
Corrective Action: See an authorized Onan dealer.

ACTUATOR OVERLOAD—CODE NO. 22

(Due to connected overload or low engine performance, the Controller maintained the governor actuator
at full-duty cycle—maximum pulse-width-modulated square-wave signal [PWM]—for
60 consecutive seconds)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-4).
4. Replace the fuel filter (p. 3-6).

4-4
 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

FAULTY ENGINE TEMPERATURE SENDER—CODE NO. 24

(After 10 minutes of normal operation the Controller checked for and sensed
an open temperature sender/harness)
Corrective Action: See an authorized Onan dealer.

VAC SENSE LOST—CODE NO. 27

(The Controller lost VAC sensing during normal voltage regulation when the field was functioning nor-
mally and frequency was at least 40 Hz)
Corrective Action: See an authorized Onan dealer.

HIGH BATTERY VOLTAGE—CODE NO. 29

(During startup the Controller sensed that battery system voltage was greater than 19.2 volts for 5 milli-
seconds or greater than 19.2 volts for 1 second will running)
Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.

STARTING FAULT—CODE NO. 32

(The Controller could not detect cranking speed [quadrature zero crossings] for 12 seconds)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
3. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.

EE CHECKSUM FAULT—CODE NO. 35

(During startup the genset Controller detected an EE memory error)
Corrective Action: See an authorized Onan dealer.

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 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

MECHANICAL FAULT—CODE NO. 36

(The Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds, though
not by Controller action)
Corrective Action:
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-4).
3. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
4. Check the engine air filter and remove any blockage (p. 3-4).
5. Replace the fuel filter (p. 3-6).

FIELD OVERLOAD—CODE NO. 38

(During normal voltage regulation Field Voltage exceeded 150 VAC for 10 seconds)
Corrective Action:
1. Reduce the number of air conditioners running at the same time, and other appliances that cause
low power factor. (The lower the power factor of a motor or compressor, the more current it draws
per kilowatt. The genset Controller, in turn, must boost field voltage to meet the higher demand for
current imposed by low power factor.)
2. Have the air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause a very low power factor.)

GENERATOR ROTOR SHORT—CODE NO. 41

(While field flashing during cranking, the Controller sensed that the rotor circuit was shorted to ground)
Corrective Action: See an authorized Onan dealer.

ROM FAULT—CODE NO. 42

(During startup the genset Controller detected a ROM memory error)
Corrective Action: See an authorized Onan dealer.

RAM FAULT—CODE NO. 43

(During startup the genset Controller detected a RAM memory error)
Corrective Action: See an authorized Onan dealer.

SPEED SENSE LOST—CODE NO. 45

(After start disconnect the Controller lost speed sense [quadrature zero crossings] for 0.25 seconds)
Corrective Action: See an authorized Onan dealer.

4-6
 TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.

LOSS OF FIELD SENSE—CODE NO. 48

(The field sense circuit on the Controller circuit board failed during normal voltage regulation)
Corrective Action: See an authorized Onan dealer.

OVERPRIME—CODE NO. 57
(The local or remote control switch was held in the Prime position for more than 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.

4-7
5. Specifications

MODEL: HDKCA HDKCB

GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,500 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 52.1 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.4 lph) 0.11 gph (0.4 lph)
Half-load 0.48 gph (1.8 lph) 0.48 gph (1.8 lph)
Full-load 1.01 gph (3.8 lph) 1.2 gph (4.5 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5°
Firing Order 1−3−2
Fuel Nozzle Injection Pressure 1991 psi (13.731 mPa)
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust (cold) 0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 5.9 quart (5.6 liter)
Cooling System Capacity 6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0° F (−17° C)
CCA (Cold Cranking Amps) 650 amps down to −20° F (−29° C)
Battery Recharging Installer must provide for battery charging
WEIGHT: 775 lbs (351 kg) 794lbs (360 kg)
SIZE (L x W x H): 41.4 x 24.5 x 27 in (105 x 62 x 68.6 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load

5-1
6. Maintenance Record

Record all periodic and unscheduled maintenance and service. See Section 3. Periodic Maintenance.

HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING

Record the name, address, and phone number of your authorized Onan service center.

6-1
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR, OnanR, the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E2008 Cummins Power Generation, Inc. All rights reserved.